Part 2
ASSEMBLY AND ADJUSTMENT OF DRIVE PINION SHAFT
1. INSTALL NEW O-ring ONTO BEARING CAGE
2. PLACE BEARING CAGE ONTO DRIVE PINION SHAFT
Be careful not to damage the oil seal with the splines.
3. INSTALL GOVERNOR DRIVE GEAR OR ROTOR SENSOR
4. INSTALL DRIVE PINION SHAFT INTO CASE
Slightly tap the cage into the case until the groove with the bore can be seen.
NOTE: Drive in the bearing cage until the surface of the bearing cage passes through the groove with the bore.
5. INSTALL SNAP RING INTO CASE
a. Using SST, install the snap ring into the groove.
SST 09350-32013 (09351-32050)
b. Slightly tap the drive pinion to fit the snap ring into the groove.
6. INSTALL OIL SLINGER
Install the oil slinger, facing the lip outward.
7. INSTALL OUTER RACE
Using SST, drive the outer race into the case.
SST 09350-32013 (09351-32100, 09351-32140)
8. INSTALL NEW SPACER
Always use a new spacer.
Install the spacer with the small end first.
9. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT
a. Place a bar at the drive pinion side and position the other end of the bar against a vise or such.
b. Drive the gear onto the shaft until the nut can be installed on the threads of the shaft.
CAUTION: Be careful not to cause an impact to the transmission case.
10. ADJUST DRIVE PINION PRELOAD
a. Coat the threads and surface of the nut with MP grease.
b. Using SST to hold the gear, tighten the nut.
Torque: 1,750 kg-cm (127 ft-lb, 172 N.m)
SST 09330-00021 and 09350-32013 (09351-32031)
c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.
Preload (at starting):
New bearing 10 - 16 kg-cm (8.7 - 13.9 in-lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)
- If the preload is greater than specified, replace the bearing spacer.
- if the preload is less than specified, retighten the nut 130 kg-cm (9 ft-lb, 1 3 N.m) at a time until the specified preload is reached.
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 2,950 kg-cm (213 ft-lb, 289 N.m)
e. If the preload is adjusted within specification, make a note of it.
INSTALLATION OF DIFFERENTIAL
1. PLACE OUTER RACE AND SELECTED ADJUSTING SHIM ONTO RH SIDE BEARING
2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.
3. INSTALL LH BEARING RETAINER
a. Install a new O-ring.
b. While holding the differential case centered with the retainer, tap in the retainer.
c. Clean the threads of the bolts and case with white gasoline.
d. Coat the threads of the bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent
e. Temporarily tighten the bolts evenly and gradually while turning the ring gear.
4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
5. TIGHTEN LH BEARING RETAINER
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
6. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload of the drive pinion shaft
Total pre load (at starting):
Add drive pinion preload (See page AT-135) ZZZZ
New bearing 2.9 4.0 kg-cm (2.5 - 3.5 in.-lb, 0.3 - 0.4 N.m)
Reused bearing 1.5 - 2.0 kg-cm (1.3 - 1.7 in.-lb, 0.1 - 0.2 N.m)
If the preload is not within specification, disassemble and readjust.
7. STAKE COUNTER DRIVEN GEAR NUT
8. INSTALL DRIVE PINION CAP
9. INSTALL CARRIER COVER
a. Clean the threads of the bolts and case with white gasoline.
b. Coat the threads of the bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent
c. Install the carrier cover over the gasket
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
POST ASSEMBLY
1. INSTALL GOVERNOR PRESSURE ADAPTOR
2. INSTALL MANUAL SHAFT AND LEVER
3. INSTALL PARKING LOCK PAWL
4. INSTALL PARKING LOCK ROD AND BRACKET
5. INSTALL INTERMEDIATE SHAFT
Install the intermediate shaft into the case while turning the counter driven gear.
NOTE: Do not damage the bushing and oil seal ring.
6. INSTALL TRANSAXLE REAR COVER WITH GASKET
Tighten the bolts.
Torque: 250 kg-cm (18 ft-lb. 25 N.m)
7. INSTALL VALVE BODY
8. INSTALL GOVERNOR BODY
9. INSTALL OIL PAN
10. INSTALL SPEEDOMETER DRIVEN GEAR
11. INSTALL NEUTRAL START SWITCH